Sustainability and circular economy principles are central to modern design and manufacturing. Planex exemplifies this with its Green Ceramics™ project. We spoke with Robert Gianello, Research Manager at Planex, to understand the journey and impact of this initiative.

Planex has long recycled materials like plastics, steel, and cardboard. However, powder coating creates microplastic waste, a significant environmental challenge. Instead of resorting to landfill, Planex repurposed this waste into Green Ceramics™.

Management at Planex, alongside others in the powder coat industry, had been seeking a solution for the waste powder problem for years. The breakthrough came with the Green Ceramics™ tiles project. Initially, Planex used the waste powder to make counterweights for cabinets, but this solution was insufficient. This led to further innovations.

"We found a way of using the waste powder to make counterweights for its cabinets," Gianello noted. "The new counterweights could not use all the waste powder, so Planex initiated and drove two more projects."

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One significant project involved testing the powder’s potential for pyrolysis to recover resources. This proof-of-concept project at Monash University demonstrated that pyrolysis could potentially solve the waste problem, though it requires widespread industry commitment. Concurrently, Planex explored using waste powder in Green Ceramics™ with UNSW's SMaRT Centre, which led to the development of environmentally-friendly ceramic products expected to be commercially available in early 2025.

"Waste powder is a valuable yet expensive and complex material," Gianello stated. "It consists of about 50% plastic, with the remainder being minerals, dyes, and inorganic fillers."

Repurposing this waste into Green Ceramics™ offers a sustainable alternative to landfills, potentially reducing environmental pollution significantly.

"Collaboration and consultation are key to a good outcome whatever the project," Gianello emphasised. "We took up the challenge and approached the university sector to address it."

The journey of Green Ceramics™ spans several years and involves numerous stakeholders, from academic institutions like Monash University and UNSW to industry giants and smaller companies. This collaborative effort highlights the necessity of a multidisciplinary approach to solving complex problems.

Planex’s Green Ceramics™ project demonstrates a commitment to sustainability and showcases the power of collaboration and innovative thinking. This initiative paves the way for significant advancements in the building sector, influencing communities and contributing to a healthier planet.

K5 is the proud sponsor of the INDE Influencer category in the 2024 programme. The shortlisted projects, such as Planex Powder-Coat Powder, embody our company ethos; create only when necessary and always consider the impacts on the future.

Innovative Sustainability and the Future of Building Materials

Sustainability and circular economy principles are central to modern design and manufacturing. Planex exemplifies this with its Green Ceramics™ project. We spoke with Robert Gianello, Research Manager at Planex, to understand the journey and impact of this initiative.

"Collaboration and consultation are key to a good outcome whatever the project," Gianello emphasised. "We took up the challenge and approached the university sector to address it."